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3D Printing Becomes Stronger and More Economical with Light and AI
<(Front) Ph.D. candidate Jisoo Nam, (Back row, from left) Ph.D. candidate Boxin Chen, Professor Miso Kim>
Photocurable 3D printing, widely used for everything from dental treatments to complex prototype manufacturing, is fast and precise but has the limitation of being fragile and easily broken by impact. A KAIST research team has developed a new technology to overcome this weakness, paving the way for the more robust and economical production of everything from medical implants to precision machine parts.
KAIST (President Kwang Hyung Lee) announced on the 29th that Professor Miso Kim's research team in the Department of Mechanical Engineering has developed a new technology that fundamentally resolves the durability limitations of photocurable 3D printing.
Digital Light Processing (DLP)-based 3D printing is a technique that uses light to solidify liquid resin (polymer) to rapidly manufacture precise structures, used in various fields such as dentistry and precision machinery. While traditional injection molding offers excellent durability, it requires significant time and cost for mold fabrication. In contrast, photocurable 3D printing allows for flexible shape realization but has a durability drawback.
Professor Kim's team solved this problem by combining two key elements:
A new photocurable resin material that absorbs shock and vibration while allowing for a wide range of properties from rubber to plastic.
A machine learning-based design technology that automatically assigns optimal strength to each part of the structure.
<Figure 1. Schematic of a new manufacturing technology for high-durability photocurable 3D printing using light-controlled gradient structures. This approach integrates the development of stiffness-controllable viscoelastic polyurethane acrylate (PUA) materials, machine learning-based property gradient optimization, and grayscale DLP 3D printing. The technology enhances damping performance and alleviates stress concentration, providing an integrated solution for high reliability, durability, and customized manufacturing. It demonstrates potential applications in structural components subjected to repetitive loads such as joints, automotive interior parts, and precision machinery components>
The research team developed a Polyurethane Acrylate (PUA) material incorporating dynamic bonds, which significantly increases shock and vibration absorption capability compared to existing materials. Furthermore, they successfully applied 'grayscale DLP' technology, which controls the light intensity to achieve different strengths from a single resin composition, thereby assigning customized strength to specific areas within the structure. This concept is inspired by the harmonious and different roles played by bone and cartilage in the human body.
A machine learning algorithm automatically proposes the optimal strength distribution by analyzing the structure and load conditions. This organically connects material development and structural design, enabling customized strength distribution.
The economic efficiency is also noteworthy. Previously, expensive 'multi-material printing' technology was required to achieve diverse material properties, but this new technology yields the same effect with a single material and a single process, significantly reducing production costs. It eliminates the need for complex equipment or material management, and the AI-based structural optimization shortens research and development time and product design costs.
Professor Miso Kim explained, "This technology simultaneously expands the degrees of freedom in material properties and structural design. Patient-specific implants will become more durable and comfortable, and precision machine parts can be manufactured more robustly." She added, "The fact that it secures economic viability by realizing various strengths with a single material and single process is highly significant," and "We anticipate its utilization across various industrial fields such as biomedical, aerospace, and robotics."
The research was spearheaded by Professor Miso Kim's team at the KAIST Department of Mechanical Engineering, with Ph.D. candidate Jisoo Nam as the first author. Boxin Chen, a student from Sungkyunkwan University, also contributed to the collaborative research. The findings were published online on July 16 in the world-renowned journal in materials science, Advanced Materials (IF 26.8). Recognizing the research's excellence, it was also selected for the journal's Frontispiece.
Paper Title: Machine Learning-Driven Grayscale Digital Light Processing for Mechanically Robust 3D-Printed Gradient Materials
DOI: 10.1002/adma.202504075
The achievements of this research have brought Professor Miso Kim significant international attention, as she simultaneously received the 'Wiley Rising Star Award' and the 'Wiley Women in Materials Science Award' in July 2025, hosted by the international academic publisher Wiley.
The Wiley Rising Star Award is given to emerging researchers with the potential for academic leadership, and the Wiley Women in Materials Science Award is a prestigious honor established to celebrate outstanding female scientists in the field of materials science.
<Figure 2. Frontispiece image (scheduled for Issue 42). Multi-property structure fabricated using a photocurable 3D printer. By varying the projector light intensity by location, stronger light creates rigid regions while weaker light forms flexible ones. AI designs an optimized pattern for the structural shape to prevent fracture and reinforce the overall strength.>
This research was supported by the National Research Foundation of Korea (NRF) grants funded by the Korean government (MSIT) (Nos. NRF-2021R1A2C2095767, RS-2023-00254689, and RS-2024-00433654).
2025.09.30 View 2333 -
KAIST Industrial Design’s Professor Sangmin Bae’s team selected as Top 20 of James Dyson Award 2024
KAIST (President Kwang-Hyung Lee) announced that the 'Oxynizer', a non-electrical medical oxygen generator for developing countries designed by Professor Sangmin Bae's team in the Department of Industrial Design, has been selected to be the Top 20 of the James Dyson Award 2024. At the same time, it was announced on the 16th that it was selected as one of the top 100 ‘Prototypes for Humanity’ 2024 and will be exhibited in Dubai in November.
< Photo 1. Photo of the award-winning team of Professor Sangmin Bae’s students of KAIST Department of Industrial Designs at the James Dyson Award 2024 announcement of the National Winners >
The James Dyson Award is a design award hosted by Sir James Dyson, founder of Dyson, and receives ideas for solving everyday problems from next-generation engineers and designers around the world, and selects and awards innovative and excellent designs every year.
The ‘Oxynizer’ developed by Professor Sangmin Bae’s team was selected as the winner of the screening within Korea in September after competing with 122 domestic teams, and was awarded a prize of 5,000 pounds for idea advancement, product development, and commercialization.
< Photo 2. A photo of Professor Sangmin Bae’s students’ award-winning achievement, ‘Oxynizer’ >
In addition, on October 16th, it was selected as one of the top 20 international winners among 1,911 competing works from 29 countries around the world. The international winner will be selected by Sir James Dyson and announced on November 13th. The international competition winner will receive a prize of £5,000, and the winner will receive an additional £30,000, giving them the opportunity to commercialize their idea.
‘Prototype for Humanity’ is a global project hosted by Art Dubai Group and carried out in collaboration with Dubai Future Foundation, Dubai Arts & Culture Authority, and Dubai International Financial Center. It is a forum for international cooperation where leading universities around the world, including Harvard University and MIT, participate to discuss global problems and solutions.
‘Oxynizer’ was selected on September 11 as one of the top 100 out of 3,000 entries submitted by universities in over 100 countries, and will be exhibited at the Jumeirah Emirates Towers of Dubai Future Foundation from November 17 to 22. The organizers will select the top five during the exhibition period, and will award a total of $100,000 in prize money to the winners to support their research.
The ‘Oxynizer’ is a device developed by students Jiwon Kim, Kyeongho Park, Seung-Jun Lee, Jiwon Lee, Yeohyeon Jeong, and Jungwoo Kim under the guidance of Professor Sangmin Bae of KAIST, and is the result of research conducted in the ‘Design Project 1’ class for the graduate students of the Department of Industrial Design at KAIST.
< Photo 3. A photo of Professor Sangmin Bae’s students’ award-winning achievement, ‘Oxynizer’ >
This device was designed to solve the problem of difficulty in supplying oxygen in developing countries due to high installation and maintenance costs. The device was designed to create concentrated oxygen to supply it to a patient in urgent need using an air pump for bicycles, which should be found more easily than a medical oxygen tank.
Professor Sangmin Bae said, “This device creates oxygen using a bicycle air pump and supplies it to patients, and it can separate water vapor and nitrogen in the air using silica gel and zeolite, which are the main materials of the filter, to supply oxygen with a concentration of up to 50%.” “In addition, the filter can be heated and reused after 120 hours of use, so it has the advantage of being able to be used semi-permanently,” he emphasized.
< Photo 4. A photo of Professor Sangmin Bae’s students’ award-winning achievement, ‘Oxynizer’ >
The results of the self-research derived from the KAIST Industrial Design Department class were selected as a world-class award winner and exhibition piece in competition with excellent universities around the world, once again proving the global competitiveness of the KAIST Industrial Design Department.
2024.10.16 View 11057 -
New Korean Robot Responds to Non-Verbal Commands
An online newspaper covering the latest headline news based on MS Windows, Internet and technology trends, Infopackets, posted an article on the research result of KAIST researchers: a robot prototype developed, which is able to respond to human’s non verbal communication.
Robots now can read human gestures and react to their subtle commands by “designing the robot’s main system to mimic the actions of a human in the same manner in which human brains function.” For details of the article, please click the link:
http://www.infopackets.com/news/technology/science/2011/20110125_new_korean_robot_responds_to_non_verbal_commands.htm
2011.01.26 View 12892 -
Professor Yang Named Recipient of Dupont Science & Technology Award
Professor Yang Named Recipient of Dupont Science & Technology Award
- Named as the recipient of Dupont Science & Technology Award of 2007- In recognition of his development of optical?bio-functional photonic crystal structures through Self-assembly of nanoparticles
Seung-Man Yang, a professor of Chemical and Biomolecular Engineering of KAIST (President Nam Pyo Suh) and the president of the National Creative Research Initiatives Center for Photon and Fluid Integrated Circuit by the Ministry of Science and Technology, has been named as the recipient of Dupont Science & Technology Award.
Dupont Korea, associate of Dupont, a world-class science firm, has established and conferred ‘Dupont Science & Technology Award’ since 2002 to promote basic sciences and industrial development of Korea. Dupont Science & Technology Awards are awarded to scientists of universities or state-run institutes who have made outstanding R&D achievements in the fields of Chemistry, Chemical Engineering, Material Science and Material Engineering within five years. Dupont Korea announced on May 2, 2007 that Professor Yang is the recipient of the award this year, following the strict examination by the Koran Academy of Science and Technology (KAST).
The reason for the award is Professor Yang’s development of prototype optical?bio-functional photonic crystal structures that can process a huge amount of data, resulting from a study that has discovered the principle of Self-assembly where multifunctional nanoparticles are manufactured and assembled for themselves.
Professor Yang’s recent research result about photon structures and nano patterns was published by Nature (February 2, 2006 edition); posted on Heart-Cut, the portal site of the American Chemistry Society (ACS), as highlight paper two times (November 4, 2002 and May 1, 2006); and introduced at Research/Researcher of MRS Bulletin by the U.S. Material Research Society (MRS) as main paper in December 2003. Professor Yang is very famous in Korea and abroad for the excellences of his research achievements and has made request seminars at Harvard University, University of Wisconsin, Caltech, University of California, etc. He is also invited speaker and session organizer of the MRS and the SPIE.
2007.05.08 View 26449